Method for molding lofted material with laminated support layer and decorative panel and garment made

ABSTRACT

A method for making a garment having a lofted assembly having an inner laminated support fabric and an outer panel and the garment produced are provided. The method includes the steps of positioning a support fabric on a lofted material; laminating the support fabric to the lofted material to form a lofted assembly; positioning the lofted assembly in a molding apparatus having at least a first mold and a second mold, closing together the first mold and the second mold thereby sandwiching the lofted assembly therebetween and while maintaining a uniform preset gap between said first mold and the second mold so that the inherent loft characteristics of the lofted assembly are substantially preserved. Then the outer panel is stitched to an outer side of said lofted assembly.

RELATED APPLICATION

This application is a continuation-in-part of application AttorneyDocket No. 0001182USQ filed on Jun. 13, 2005; which is acontinuation-in-part of U.S. application Ser. No. 10/631,474, filed onJul. 31, 2003.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for molding garments and thegarments made. More particularly, the present invention relates to amethod for molding a lofted material having a laminated support layer andecorative panel and the resultant garment.

2. Description of the Prior Art

Various methods and mechanisms for molding different types andassemblies of material have been developed and are known. For example,U.S. Pat. No. 3,464,418 provides an apparatus and method for makingbrassiere pads from bonded non-woven fibrous batting material, U.S. Pat.No. 4,025,597 provides a method of making a brassiere cup from a softfibrous board material, U.S. Pat. No. 4,080,416 provides a method formaking multi-layered seamless brassiere pads, and U.S. Pat. No.4,250,137, which provides a process for preparing breast pads or frontssuch that the pads are centrally soft and peripherally firmer.

Notwithstanding that which is known, there remains a continuing need forimproved methods for molding lofted material having a laminated supportlayer to provide a three dimensional shape thereto without compromisingthe loft characteristics associated with such material. Problemsheretofore associated with various processes of molding a loftedmaterial include at least the following: (1) thinning of material atpoints of increased pressure or applied heat, or both, such as forexample, the apex of a bra cup or pad, (2) requiring relativelycomplicated or additional structural elements, or both to facilitate adesired result, for example, spacer devices or vacuum systems, and (3)requiring that heat, pressure or both be avoided at relativelysubstantial portions of the material being molded, which can complicatethe molding process.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide method for moldinglofted assembly having an inner laminated support layer that isconnected to an outer panel.

It is another object of the present invention to provide a garment thatis made from a lofted material that has a inner laminated support layerthat is molded to maintain the loft characteristics of such loftedmaterial and an outer panel.

It is yet another object of the present invention to provide a garmentthat is molded from a lofted material that has an inner laminatedsupport layer and a decorative outer panel.

It is still yet another object of the present invention to provide abrassiere that is molded from a lofted assembly having a lofted materialand an inner laminated synthetic support layer and a decorative panelthat is molded to provide support for a average to large sizedbrassieres.

These and other objects and advantages of the present invention areachieved by a molding apparatus with at least a first die or mold with aprojecting element and a first level portion, and a second die or moldwith a recessed element and a second level portion. The projectingelement and the recessed element are formed such that when the firstlevel portion of the first mold and the second level portion of thesecond mold are brought into relatively close relation, a uniform presetdistance or gap is created between the projecting element and therecessed element. The gap is preferably adjustable to accommodate theloft of different materials. The first mold and second mold each arepreferably selectively and/or independently heatable and configured asappropriate to facilitate the following material molding method.

The method for molding the lofted material essentially comprises thesteps of first placing a pre-cut support layer that is in apre-determined position on a piece of lofted material, laminating thetwo materials together to form a lofted assembly, and positioning thelofted assembly in the molding apparatus. Then, closing the first moldin relation to the second mold, or vice-versa, sandwiching the loftedassembly therebetween such that the portion of the lofted assemblysituated between the first and second level portions is compressed andthe portion of the lofted assembly situated between the projectingelement and recessed element is compressed only to the extent desired ornot at all. The extent of compression being adjustable. Following thisclosing step is a step of opening the first mold in relation to thesecond mold after a period of selectively providing pressure and/or heatas appropriate for the desired molding result. Then stitched to themolded lofted assembly on an opposite side from the support layer is anouter preferably, decorative panel. The resulting molded lofted assemblypreferably provides a balance of comfort, support, durability andaesthetic appeal.

BRIEF DESCRIPTION OF THE DRAWINGS

Other and further objects, advantages and features of the presentinvention will be understood by reference to the following specificationin conjunction with the accompanying drawings, in which like referencecharacters denote like elements of structure.

FIG. 1 is a top view of the lofted material that is to be molded inaccordance with an illustrative embodiment of the present invention;

FIG. 2 is a top view of the pre-cut synthetic support layer that is tobe laminated to the lofted material in accordance with the presentinvention;

FIG. 3 is top view of the laminated assembly of lofted material and thesynthetic support layer in accordance with the present invention;

FIG. 4 is a cross-sectional side view of an apparatus for molding alofted assembly in accordance with an illustrative embodiment of thepresent invention with the apparatus shown in open position;

FIG. 5 is a cross-sectional side view of the apparatus of FIG. 4 withthe apparatus shown in a closed position;

FIG. 6 is a side sectional view of the apparatus of FIG. 4, reflecting aforming step in accordance with an illustrative embodiment of thepresent invention;

FIG. 7 is a side sectional view of an alternative apparatus for moldinga lofted assembly;

FIG. 8 is a side sectional view of another alternative apparatus formolding a lofted assembly;

FIG. 9 is a plan view of yet another alternative apparatus for molding alofted assembly;

FIG. 10 is a plan view of still another alternative apparatus formolding a lofted assembly;

FIG. 11 is a side sectional view of yet still another alternativeapparatus for molding a lofted assembly;

FIG. 12 is a rear view of the lofted assembly molded in the form of abreast-receiving cup; and

FIG. 13 is a front view of the lofted assembly molded in the form of thebreast-receiving cup with the decorative panel.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings and, in particular to FIG. 1, there is shownan illustrative embodiment of the lofted material generally representedby reference numeral 30. In this disclosure, the term lofted material 30includes foam and circularly knitted and/or warp knitted single plymaterials that can be a variety of materials or combination of materials(batting, spacer fabric, etc.). Spacer fabric could be a polyesterand/or nylon fabric. Lofted material 30 has a inner side or first side31 that contacts the skin of the wearer and an outer side or second side33 that faces in an outward direction opposite inner side 31. Loftedmaterial 30 is sized to form a deep breast-receiving cup for a brassiereafter being molded.

Referring to FIG. 2, support layer 35 is shown. Support layer 35 is cutin the shape of a crescent to ensure a comfortable and close fit at thelower lateral inner surface portion of the finished breast-receivingcup. Although the shape of support layer 35 is shown as a crescent,other shapes capable of offering comfort and support to the wearer couldalso be used. Support layer 35 can be any synthetic material or naturalmaterial. Preferably, the support fabric 35 is a warp knit material. Inall instances, support layer 35 provides the level of comfort andsupport to the breasts of the wearer that would otherwise not beavailable without the enhanced support.

In FIG. 3, support layer 35 is pre-positioned on lofted material 30 oninner side 31 before the two pieces of fabric are laminated together.The temperature that is required to laminate support layer and loftedmaterial 30 is approximately 320° F. to 360° F. The lamination processis of a temperature that will preserve the loft and the aesthetic appealof the lofted material 30 and support layer 35. After the laminationprocess, lofted material 30 and support layer 35 together form loftedassembly 36.

Referring to the drawings and, in particular to FIG. 4, there is shownan illustrative embodiment of an apparatus for molding lofted assembly36. The apparatus 1 preferably has at least two mold elements, a firstmold 10 and a second mold 20. Preferably, the first mold 10 and thesecond mold 20 are complementary to one another.

Preferably, first mold 10 and second mold 20 cooperate to mold or form alofted assembly 36 positioned therebetween into a three-dimensionalshape, such as, for example, that required by molded brassiere pads.Preferably, lofted assembly 36 can be any of a variety of materials orcombination of materials and can be fashioned into a variety of forms,such as for example, a garment.

First mold 10 preferably has at least one first contact surface 40 withat least one projecting element 50 in the form of a dome. First contactsurface 40 preferably also has a first level portion 42 about projectingelement 50. First contact surface 40 may also have any of a variety ofother surface elements 43 associated therewith, such as for example, oneor more nodes, dimples, and/or teeth as shown in FIGS. 9 through 11.First contact surface 40 can be interchangeably associated with firstmold 10. First mold 10 can be interchangeably associated with apparatus1. The interchangeability of first contact surface 40 and/or first mold10 preferably provides apparatus 1 with further diversity in applicationor use.

Preferably, first mold 10, first contact surface 40, projecting element50, and/or first level portion 42 can be heatable. This heating can beaccomplished in any of a variety of ways, such as for example, viaelectric heating wires or rods associated with first mold 10. Theseheating wires or rods could preferably conduct or transmit heat, viafirst mold 10, as appropriate, to provide any and/or all of theaforementioned elements thereof with sufficient heat for effectivemolding under a variety of different molding parameters. First mold 10can preferably have any shape, size, and/or configuration suitable foraccomplishing one or more different molding operations. See, forexample, FIGS. 7 and 8, which show alternative embodiments of first mold10. It is noted that the present invention is not limited to thoseconfigurations discussed and/or shown and that other configurations arealso within the scope of the present invention.

It is also noted, with regard to surface elements 43 discussed above,that surface elements 43 are preferably suitable for achieving a varietyof different molding effects. For example, surface elements 43 can be oneither and/or both projecting element 50 and first level portion 42 tointeract with lofted assembly 36 during a molding process. Surfaceelements 43 can be, for example, one or more piercing elements, heatingor cooling elements, cushioning or insulating elements, or anycombination of the same. Other similar types of elements may also beused and are within the scope of the present invention.

Referring again to FIG. 4, second mold 20 has at least one secondcontact surface 60 with at least one recessed element 70 in the form ofa dish. Preferably, recessed element 70 is complementary to andcooperative with projecting element 50 of first mold 10. Second contactsurface 60 preferably also has a second level portion 62 about recessedelement 70. Second contact surface 60 may also have surface elements 43associated therewith. Second contact surface 60 can be interchangeablyassociated with second mold 20, and, the second mold can beinterchangeably associated with apparatus 1. The interchangeability ofsecond contact surface 60 and/or second mold 20 preferably providesapparatus 1 with further diversity in application or use.

Preferably, second mold 20, second contact surface 60, recessed element70, and/or second level portion 62 can be heatable. Such heating can beaccomplished in any of a variety of ways, such as, for example, byelectric heating wires or rods associated with second mold 20. Theseheating wires or rods could preferably conduct or transmit heat, viasecond mold 20, as appropriate to provide any and/or all of theaforementioned elements thereof with sufficient heat for effectivemolding under a variety of different molding parameters. Second mold 20can preferably have any shape, size, and/or configuration suitable foraccomplishing one or more different molding operations in cooperationwith mold 10. See, for example, FIGS. 7 and 8, which show alternativeembodiments of second mold 20. It is noted that the present invention isnot limited to those configurations discussed and/or shown and thatother configurations are also within the scope of the present invention.

As with the first mold 10, surface elements 43 for providing a varietyof different molding effects that can be on either and/or both recessedelement 70 and second level portion 62 to interact with lofted assembly36 during the molding process.

Referring to FIGS. 5 and 6, having described some of the preferredelements of an illustrative embodiment of the present invention, firstand second molds 10, 20, respectively, are preferably configured toengage one another such that when first level portion 42 of first mold10 and second level portion 62 of second mold 20 are brought intorelatively close relation, a uniform preset distance or gap 80 iscreated between projecting element 50 and recessed element 70. Gap 80preferably has an extent of about 0.1 inches. However, gap 80 can alsohave any extent appropriate for accomplishing a desired moldingoperation. Hence, gap 80 can preferably be adjusted to accommodate theloft characteristics associated with a variety of different materials.This adjusting feature can be accomplished in different ways, such as,for example, via the preferred interchangeability of first and secondmolds 10, 20 and/or first and second contacting surfaces 42, 62. Gap 80may also be adjusted to influence the degree of loft associated with amaterial. That is, gap 80 can be reduced to provide a desired finish oreffect to a lofted assembly 36. Thus, it is apparent the preservation ofthe inherent loft characteristics associated with a lofted assembly ispreferably independent of the heat, pressure and/or time associated witha particular molding process. The present invention efficiently andeffectively preserves the inherent loft characteristics associated witha lofted assembly during the molding process.

The process of molding lofted assembly 36 preferably includes at leastthe following steps. Referring to FIGS. 1 and 4 through 6, loftedassembly 36 is first positioned in apparatus 1 between first mold 10 andsecond mold 20. Lofted assembly 36 is positioned in apparatus 1 suchthat inner side 31 having support layer 35 is facing projecting element50. On lofted assembly 36, support layer 35 is positioned so that afterthe molding process, support layer 35 will be positioned at the lowerlateral inner side edge of lofted assembly 36. Referring to FIG. 2,first mold 10 is then closed in relation to second mold 20, orvice-versa, to sandwich lofted assembly 36 therebetween. Preferably, atleast a portion of lofted material 30 is situated in gap 80 so that theinherent loft characteristics thereof are substantially preserved whileat least another portion of lofted assembly 36 is substantiallycompressed between first and second level portions 42, 62 of first andsecond contact surfaces 40, 60, respectfully. Next, first mold 10 isopened in relation to second mold 20, or vice-versa, after anappropriate amount of heat and/or pressure has been applied for anappropriate period of time. Referring to FIG. 12, formed lofted assembly92 is removed from apparatus 1 to perform any additional operationsrequired for obtaining a desired effect, such as for example, adding anouter panel or an outer decorative panel or eliminating any excess orunwanted material as appropriate to leave formed lofted assembly 92 witha three dimensional shape.

Referring to FIGS. 12 and 13, finished cup 95 is shown. Cup 95 has afirst or inner side 93 and a second or outer side 94. First or innerside 93 has support layer 35 connected at a lower lateral edge andsecond or outer side 94 has an outer panel 37 connected to a lowerlateral edge in a position that is opposite support layer 35. Outerpanel 37 is preferably crescent shaped. Outer panel 37 is preferablylace although, other materials such Jacquard, woven or knitted materialscould also be used. Outer panel 37 is preferably decorative and can haveany design such as, for example, a floral design or a geometric pattern,although any pattern could be used. Panel 37 is connected to breastreceiving cup 95 preferably by stitching although other methods forconnecting decorative panel that preserve the aesthetic appeal of breastreceiving cup 95 could also be used. Together lofted material 36,support layer 35 and decorative panel 37 form finished cup 95.

Referring to FIG. 13, the molding process of cup 95 results in a moldedcup for a brassiere that accommodates wearers needing from average tolarge sized brassieres. Such a brassiere may include such conventionalelements as side panels connected to one of a pair of breast receivingcups and shoulder straps connected to a separate one of a pair of breastreceiving cups. The material of support layer 35 is of such stitchpattern and material that it limits the elasticity of the loftedmaterial 30 from which cup 95 is made. By limiting the elasticity of thelofted material 30, wearers that require substantial breast support canwear cup 95 with comfort and confidence.

The present invention having been thus described with particularreference to the preferred forms thereof, it will be obvious thatvarious changes and modifications may be made therein without departingfrom the spirit and scope of the present invention as defined herein.

1. A method for molding a lofted assembly comprising the steps of:positioning a support layer on a first side of a lofted material;laminating said support layer to said lofted material to form saidlofted assembly; positioning said lofted assembly in a molding apparatushaving at least a first mold and a second mold, said first mold having asurface with a projecting element and a first level portion and saidsecond mold having a surface with a recessed element and second levelportion, said projecting element being formed to fit in said recessedelement when said first mold and said second mold are brought intorelatively close relation; closing together said first mold and saidsecond mold thereby sandwiching said lofted material between said firstlevel portion and said second level portion while maintaining a uniformpreset gap between said projecting element and said recessed element sothat the inherent loft characteristics of said lofted material aresubstantially preserved; opening in relation to each other said firstmold and said second mold, or vice-versa, and removing the loftedassembly from said apparatus; and connecting an outer panel to a secondside of said lofted assembly that is opposite said first side.
 2. Themethod of claim 1, wherein said step of connecting said outer panelcomprises stitching said outer panel to a second side of said loftedassembly that is opposite said first side.
 3. The method of claim 1,wherein said step of connected said outer panel is after said step ofremoving said molded lofted assembly from said apparatus.
 4. The methodof claim 1, wherein said outer panel is a decorative panel.
 5. Themethod of claim 1, further comprising the step of: eliminating anyexcess material as appropriate to leave a molded lofted assembly with athree dimensional shape.
 6. The method of claim 1, wherein said firstmold, said second mold, or both are independently and selectivelyheatable.
 7. The method of claim 1, wherein said projecting element,said recessed element, or both are independently and selectivelyheatable.
 8. The method of claim 1, wherein said first mold, said secondmold, or both have one or more surface elements.
 9. The method of claim8, wherein said one or more surface elements of said first mold areassociated with said projecting element, and wherein said one or moresurface elements of said second mold are associated with said recessedelement to interact with said one or more surface elements of said firstmold.
 10. The method of claim 8, wherein said one or more surfaceelements are heatable.
 11. The method of claim 8, wherein said one ormore surface elements are uniformly distributed over said first mold,said second mold, or both.
 12. The method of claim 1, wherein saidlaminating step occurs at a temperature of approximately 320° F. to 360°F.
 13. A molded garment comprising: a lofted material having a innerside and an outer side opposite said inner side; a support layer; and anouter panel; wherein said support layer is laminated to said inner sideof said lofted material and said outer panel is connected to said outerside of said lofted material to form a breast receiving cup.
 14. Themolded garment of claim 13, wherein said support layer is crescentshaped.
 15. The molded garment of claim 13, wherein said outer panel iscrescent shaped.
 16. The molded garment of claim 13, wherein said outerpanel is a decorative panel.
 17. The molded garment of claim 13, whereinsaid support layer is selected from the group consisting of a syntheticfabric, a natural fabric or any combination thereof.
 18. The moldedgarment of claim 13, wherein said support layer is warp knitted.
 19. Themolded garment of claim 13, wherein said lofted material is selectedfrom the group consisting of foam, spacer fabric and, circularly knittedand/or warp knitted single ply materials spacer fabric.
 20. The moldedgarment of claim 13, wherein said outer panel is selected from thematerials consisting of woven material, lace, knit material or Jacquardmaterial.
 21. The molded garment of claim 13, wherein said garmentcomprises a brassiere.
 22. A brassier comprising: a pair of breastreceiving cups; a pair of side panels, each being connected to aseparate of said pair of breast cups wherein each of said pair of breastreceiving cups has a support layer, an outer panel and a loftedmaterial; wherein said lofted material has an inner side and an outerside, said support layer being laminated and molded to said inner sideand said outer panel being connected to said outer side; and and a pairof shoulder straps, each being connected to a separate one of said pairof breast receiving cups.
 23. The brassiere of claim 22, wherein saidouter panel is stitched to said lofted material.
 24. The brassiere ofclaim 22, wherein said support layer is crescent shaped.
 25. Thebrassiere of claim 22, wherein said support layer is at a lateralportion of each of said pair of breast receiving cups.
 26. The brassiereof claim 22, wherein said support layer is selected from the groupconsisting of synthetic fabric, natural fabric or any combinationthereof.
 27. The brassiere of claim 22, wherein said support layer iswarp knitted.
 28. The brassiere of claim 22, wherein said loftedmaterial is selected from the group consisting of foam, spacer fabricand, circularly knitted and/or warp knitted single ply materials spacerfabric.
 29. The brassiere of claim 22, wherein said outer panel isselected from the group consisting of woven material, lace, knittedmaterial or Jacquard material.
 30. The brassiere of claim 29, whereinsaid outer panel is a decorative panel.